Gentle Giant Studios

Gentle Giant Studios Finds "The Force"
With Solid Imaging Technology

Solid imaging technology is the future of three-dimensional product development, according to Karl Meyer, president of Gentle Giant Studios of Burbank, California. Meyer should know. His company is one of the leading 3-D modeling studios serving Southern California’s entertainment industry, along with the toy industry that merchandises licensed entertainment products on a worldwide basis.

The company makes 3-D models for numerous applications, ranging from special effects to consumer products. Recently, Gentle Giant completed more than 250 pieces of merchandise for Star Wars Episode 1. The studio also does a host of business related to product licensing for companies such as Disney and Warner Brothers.

Finding the Best Solution
In 1997, Meyer began to research 3-D printing systems as a means to speed and improve productivity at the studio. Using a traditional modeling process, models are hand-sculpted from wax; a very craft-intensive and time-consuming task. "Models generally require a multitude of iterations, which is a lengthy process with hand sculpting," says Meyer. After exploring the market alternatives, Gentle Giant purchased two Actua® 2100 printers and the SLA® 250 system from 3D Systems. "Solid imaging technology was an excellent solution for us, as we could generate models quickly and easily right in our shop."

Meyer has since acquired two ThermoJet printers from 3D Systems. The ThermoJet printer uses similar technology as the Actua printer but boasts greater productivity, increasing part building speed by three-fold. The ThermoJet system also utilizes a material that is twice as durable as the Actua material. The ThermoJet printer is a cost-effective 3-D printer developed for CAD operators in a design office environment. Much like a network printer, it uses technology that is based on ink jet printing—but instead of ink it sprays a plastic-like substance to create a solid model. Layer by layer, a three-dimensional object is formed that can be held and evaluated. The part then becomes a real-world example of what may be difficult to comprehend when viewed as a complex CAD image on a computer screen. Gentle Giant uses the ThermoJet printer to augment its production process. Beginning with a hand-sculpted wax model, the model is then three dimensionally scanned and a CAD file is generated.

"Because of this equipment, we can take on more projects, generate more product, and grow the business more effectively.”
                                                                          Karl Meyer,
                                                                          Gentle Giant Studios

The CAD file can then be manipulated to create several variations of the initial object. Then the objects are printed on the ThermoJet printer, and these 3-D prints serve as patterns to create molds. For parts that need to be particularly strong and rigid right off the machine, Meyer uses his SLA 250 system, the world’s most widely used solid imaging system. According to Meyer, there are certain designs that work particularly well on the SLA system—such as thin walled parts with small details and functional prototypes. SLA systems utilize a technology called stereolithography, in which a laser beam hardens a pool of liquid epoxy plastic, layer by layer, until a solid three-dimensional object is formed. "We’re currently creating maquettes for 20th Century Fox for a feature animation movie that’s scheduled to come out next year," says Meyer. "We sculpted the actual characters by hand in clay and used a 3-D scanner to scan them in for later reproduction. Using the animation data, we are able to build parts on the SLA machine that are just perfect, while maintaining the integrity of the characters."

Iterating Easily and Quickly
Flexibility and speed are the factors that Meyer cites as major benefits of integrating these machines into production. "If we’re working on a Buzz Lightyear figurine, and we’re not sure what size the piece needs to be, we can produce a dozen different sizes and pick and choose without reconstruction," he notes. "We can do mirror imaging and inverting—and save time by applying these techniques as well. Sometimes it takes 50 arms to find the one that’s right for a character." Compared to production before the incorporation of 3D Systems’ equipment, the speed of execution has increased ten-fold or greater.